Articles comprising impregnated thermoplastic members and method of manufacturing the articles

Abstract

An article, including disposable articles and durable articles, includes one or more shaped thermoplastic members, which can be at least partially impregnated into one or more fibrous substrates forming a composite material of the article having regions of breathability, elasticity, and/or stiffening to provide desired functions of the article. The shaped thermoplastic members have a profiled thickness and/or basis weight providing variation in material properties. A percent variation of the profiled thickness of the thermoplastic member can vary from about 5% to about 95%. A process for manufacturing the composite material of the present invention is also disclosed.

What is claimed is: 
     
       1. A method of making a composite material comprising at least one shaped thermoplastic member impregnated into at least one fibrous substrate, the method comprising the steps of:
 providing a first fibrous substrate; 
 depositing a first thermoplastic material on the first fibrous substrate using a rotogravure printing device to form a first shaped thermoplastic member having a profiled thickness providing variation in material properties, wherein a percent variation of the profiled thickness of the thermoplastic member can vary from about 5% to about 95%; 
 providing a second substrate; 
 depositing a second thermoplastic material on the second fibrous substrate to form a second shaped thermoplastic member; 
 combining the first substrate and the second substrate to form the composite material, wherein the first thermoplastic member is at least partially impregnated into the first substrate; and 
 impregnating the first and second shaped thermoplastic member into the first and second substrates by advancing the composite material through a pair of nip rolls. 
 
     
     
       2. The method of  claim 1 , wherein the thermoplastic material is at least partially impregnated into the second substrate. 
     
     
       3. The method of  claim 1 , wherein the percent variation varies from 20% to 80%. 
     
     
       4. The method of  claim 1 , wherein the second substrate is not fibrous. 
     
     
       5. The method of  claim 1 , wherein the second substrate is fibrous. 
     
     
       6. The method of  claim 1  wherein the step of depositing is selected from a group consisting of intaglio printing, gravure printing, screen-printing, ink jet printing, and flexographic printing. 
     
     
       7. The method of  claim 6 , wherein the first thermoplastic member and the second thermoplastic member are different materials. 
     
     
       8. A method of making a composite material comprising at least one shaped thermoplastic member impregnated into at least one fibrous substrate, the method comprising the steps of:
 providing a first fibrous substrate; 
 depositing a first thermoplastic material on the first fibrous substrate using a to form a first shaped thermoplastic member having a profiled thickness providing variation in material properties, wherein a percent variation of the profiled thickness of the thermoplastic member can vary from about 5% to about 95%; 
 providing a second substrate; 
 depositing a second shaped thermoplastic member on the first fibrous substrate on top of the first shaped thermoplastic member; 
 combining the first substrate and the second substrate to form the composite material, wherein the first thermoplastic member is at least partially impregnated into the first substrate; and 
 impregnating the first and second shaped thermoplastic member into the first and second substrates by advancing the composite material through a pair of nip rolls. 
 
     
     
       9. The method of  claim 8  wherein the step of depositing the second shaped thermoplastic member is selected from a group consisting of gravure printing, screen-printing, ink jet printing, and flexographic printing. 
     
     
       10. The method of  claim 8 , wherein the first shaped thermoplastic member and the second shaped thermoplastic member are different materials. 
     
     
       11. The method of  claim 8 , wherein the first shaped thermoplastic member and the second shaped thermoplastic member are same materials.